Image source unit and display device

ABSTRACT

A laminate including: a base material layer, an optical functional layer, and a polarizing plate; wherein the optical functional layer includes a plurality of light transmissive portions extending in one direction along a face of the base material layer, and arrayed in a direction different from an extending direction thereof, and an in-between portion(s) formed in the intervals of adjacent light transmissive portions, an angle formed by an extending direction of the transmission axis of the polarizing plate, and the extending direction of the light transmissive portions is 1° to 41.7° in a front view, the base material layer is formed of polycarbonate, and the average coefficient of linear expansion or the average linear expansion of the laminate is within a predetermined range.

TECHNICAL FIELD

The present disclosure relates to laminates, image source units and display devices for providing images for observers.

BACKGROUND ART

In a display device such as a liquid crystal television, a surface light source device illuminates a liquid crystal panel which has image information, from the back face side of the liquid crystal panel. This makes the illuminating light pass through the liquid crystal panel to obtain the image information, and is emitted to the observer side, which makes it possible for observers to see images. On the other hand, the liquid crystal panel, because of its nature, has a limitation in light which can be effectively used. Therefore improvements for efficiently using light from the light source are demanded.

JP2010-217871A discloses an image source unit in which a surface light source, a prism sheet, an optical functional layer (a layer where light transmissive portions and light absorbing portions are alternately arranged), and a liquid crystal panel are layered in the order mentioned. This makes the directions of light entering the liquid crystal panel closer to the normal line of the panel face of the liquid crystal panel, whereby the use efficiency of the light is increased.

Japanese Unexamined Patent Application Publication No. 2011-501219 also discloses a structure in which a light source, a brightness enhancement film (a sheet where a plurality of prisms whose apexes face to the observer side are arranged), a reflection polarizing film, an LCF (a film where light transmissive portions and light absorbing portions are alternately arranged), a liquid crystal panel are arranged in the order mentioned. This makes it possible to make the direction of light emitted from the light source closer to the normal direction of the panel face of the liquid crystal panel, therefore it is said that the use efficiency of light can be increased. In addition, the light entered the LCF having a large angle to the panel face of the liquid crystal panel is absorbed by the light absorbing portions arranged in the LCF.

SUMMARY OF INVENTION Technical Problem

However, the optical functional layers described in JP2010-217871A and Japanese Unexamined Patent Application Publication No. 2011-501219 (LCF in Japanese Unexamined Patent Application Publication No. 2011-501219) may absorb part of effective light because they have light absorbing portions as in-between portions, between light transmissive portions.

In addition, since the optical functional layer has stripe patterns by the light transmissive portions and the light absorbing portions. Therefore the optical functional layer sometimes causes moire interference fringes by the relationship with the pixels of the liquid crystal panel.

Considering the above problems, an object of the present disclosure is to provide a laminate that can improve use efficiency of light from light sources and can increase the quality of the screen, even though the laminate has a layer including light transmissive portions and in-between portions.

Solution to Problem

A first aspect of the present disclosure is a laminate comprising: a polarizing plate; and an optical sheet arranged on one surface side of the polarizing plate, wherein the optical sheet includes a base material layer, and an optical functional layer arranged on one face of the base material layer, the optical functional layer includes a plurality of light transmissive portions extending in one direction along a face of the base material layer, each having a predetermined cross section, and arrayed in a direction different from an extending direction thereof at predetermined intervals, and an in-between portion(s) formed in each of the intervals of adjacent light transmissive portions, an angle formed by an extending direction of a transmission axis of the polarizing plate, and the extending direction of the light transmissive portions is 1° to 41.7° in a front view of the laminate, and the base material layer is formed of polycarbonate, and an average coefficient of linear expansion of the laminate within a range of −50° C. and 130° C. is 0 (1/° C.) to 1×10⁻⁴ (1/° C.).

Another aspect of the present disclosure is a laminate comprising: a reflection type polarizing plate; and an optical sheet arranged on one surface side of the reflection type polarizing plate, wherein the optical sheet includes a base material layer, and an optical functional layer arranged on one face of the base material layer, the optical functional layer includes a plurality of light transmissive portions extending in one direction along a face of the base material layer, each having a predetermined cross section, and arrayed in a direction different from an extending direction thereof at predetermined intervals, and an in-between portion(s) formed in each of the intervals of adjacent light transmissive portions, an angle formed by an extending direction of a transmission axis of the reflection type polarizing plate, and the extending direction of the light transmissive portions is 1° to 41.7° in a front view of the laminate, and the base material layer is formed of polycarbonate, and an average coefficient of linear expansion of the laminate within a range of −50° C. and 130° C. is 0 (1/° C.) to 1×10⁻⁴ (1/° C.).

Another aspect of the present disclosure is a laminate comprising: a polarizing plate; and an optical sheet arranged on one surface side of the polarizing plate, wherein the optical sheet includes a base material layer, and an optical functional layer arranged on one face of the base material layer, the optical functional layer includes a plurality of light transmissive portions extending in one direction along a face of the base material layer, each having a predetermined cross section, and arrayed in a direction different from an extending direction thereof at predetermined intervals, and an in-between portion(s) formed in each of the intervals of adjacent light transmissive portions, an angle formed by an extending direction of a transmission axis of the polarizing plate, and the extending direction of the light transmissive portions is 1° to 41.7° in a front view of the laminate, and the base material layer is formed of polycarbonate, and an average linear expansion of the laminate within a range of −50° C. and 130° C. is 0% to 2%.

Another aspect of the present disclosure is a laminate comprising: a reflection type polarizing plate; and an optical sheet arranged on one surface side of the reflection type polarizing plate, wherein the optical sheet includes a base material layer, and an optical functional layer arranged on one face of the base material layer, the optical functional layer includes a plurality of light transmissive portions extending in one direction along a face of the base material layer, each having a predetermined cross section, and arrayed in a direction different from an extending direction thereof at predetermined intervals, and an in-between portion(s) formed in each of the intervals of adjacent light transmissive portions, an angle formed by an extending direction of a transmission axis of the reflection type polarizing plate, and the extending direction of the light transmissive portions is 1° to 41.7° in a front view of the laminate, and the base material layer is formed of polycarbonate, and an average linear expansion of the laminate within a range of −50° C. and 130° C. is 0% to 2%.

An image source unit may comprise the laminate further including a liquid crystal layer.

A display device may be formed of a housing in which the image source unit is placed.

Advantageous Effects of Invention

According to the present disclosure, it is possible to efficiently emit appropriate light, and at the same time to effectively absorb light that causes defects, to whereby improve the use efficiency of light.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view showing an image source unit 10 according to a first embodiment;

FIG. 2 is a cross-sectional view of the image source unit 10;

FIG. 3 is another cross-sectional view of the image source unit 10;

FIG. 4 is a view showing one embodiment of a prism layer 27;

FIG. 5A is a view showing a prism layer 27′;

FIG. 5B is a view showing a prism layer 27″;

FIG. 6 is a view showing a light polarizing sheet 28′;

FIG. 7 is an enlarged view of a part of an optical sheet 30 of FIG. 2;

FIG. 8 is a view showing an angle θ_(s) formed by an extending direction of a light transmissive portion 33 and an extending direction of a transmission axis of a lower polarizing plate 14;

FIG. 9 is a view showing a layer 31′ having a rough face;

FIG. 10 is an enlarged cross-sectional view of a part of an optical sheet 130;

FIG. 11 is an enlarged cross-sectional view of a part of an optical sheet 230;

FIG. 12 is a perspective view showing an images source unit 310;

FIG. 13 is a graph showing a relationship between θ_(s) and a transmittance ratio T_(p);

FIG. 14 is a perspective view showing an image source unit 410;

FIG. 15 is a cross-sectional view of the image source unit 410;

FIG. 16 is a view showing an optical element layer 436;

FIG. 17 is a cross-sectional view of an image source unit 510; and

FIG. 18 is a view showing a prism sheet A.

DESCRIPTION OF EMBODIMENTS

Hereinafter each embodiment will be described based on the drawings. However, this invention is not limited to these embodiments. In each drawing shown below, sizes and shapes of members may be overdrawn for the purpose of easy understanding, and repeating symbols may be omitted for the purpose of easy reading.

FIG. 1 is a view to explain a first embodiment, which is a perspective view of an image source unit 10 included in a display device. FIG. 2 shows a part of a cross-sectional view of the image source unit cut along the line shown by II-II in FIG. 1. FIG. 3 shows a part of a cross-sectional view of the image source unit 10 cut along the line III-III shown in FIG. 3. Other than the image source unit 10, the display device includes general devices needed for operating as a display device, such as a housing for placing the image source unit, a power source for activating the image source unit, and an electronic circuit for controlling the image source unit, whose descriptions are omitted. Hereinafter the image source unit 10 will be described.

The image source unit 10 includes a liquid crystal panel 15, a surface light source device 20, and a functional film 40. In FIG. 1, the upper side of the drawing sheet is the observer side. That is, the image source unit 10 includes a laminate that is formed of laminated layers each having various functions.

The liquid crystal panel 15 includes an upper polarizing plate 13 that is a polarizing plate arranged on the functional film 40 side (observer side), a lower polarizing plate 14 that is a polarizing plate arranged on the surface light source device 20 side, and a liquid crystal layer 12 arranged between the upper polarizing plate 13 and the lower polarizing plate 14. The upper polarizing plate 13 and the lower polarizing plate 14 have a function to: divide incident light into two polarization components (P wave and S wave) that are orthogonal to each other; transmit the polarization component (for example, P wave) of one direction (a direction parallel to a transmission axis); and absorb the polarization component (for example, S wave) of the other direction (a direction parallel to an absorption axis) which is orthogonal to the above direction.

In the liquid crystal layer 12, a plurality of pixels are arranged in a vertical direction and horizontal direction along the layer face, and an electric field may be applied on a region to region basis, each region forming one pixel. The orientation of the liquid crystal layer 12 in which the electric field is applied varies. The polarization component (for example, P wave) parallel to the transmission axis transmitted through the lower polarizing plate 14 arranged on the surface light source device 20 side (that is, the light input side), rotates the polarization direction thereof by 90° C. when passing through the pixel in which the electric field is applied, whereas maintaining the polarization direction thereof when passing through the pixel in which the electric field is not applied. As such, based on whether the electric field is applied or not, it is possible to control whether the polarization component (for example, P wave) transmitted through the lower polarizing plate 14 is further transmitted through the upper polarizing plate 13 arranged on the light output side of the lower polarizing plate 14, or is absorbed and blocked by the upper polarizing plate 13.

In this way, the liquid crystal panel 15 has a structure for controlling, on a pixel to pixel basis, transmission or blocking of the light emitted from the surface light source device 20 to display an image.

The liquid crystal panel is configured to be capable of providing images to observers with this structure. Therefore, when lighting is provided from the back face side of the liquid crystal panel, it is possible to improve the use efficiency of light by bringing a lot of light having the polarization component parallel to the transmission axis of the lower polarizing plate to the lower polarizing plate and making the light pass through the lower polarizing plate.

Further, the liquid crystal panel has a good contrast of emitted light and efficiency (transmittance), for incident light from the normal direction of the liquid crystal panel, by its nature. However, regarding incident light having large angles to the normal direction of the liquid crystal panel, and observation by the observer from an oblique direction, the crystal panel has problems of low contrast and low efficiency (transmittance). That is, increasing incident light from the normal direction of the liquid crystal panel is also effective to increase the use efficiency of light.

The kind of the liquid crystal panel is not particularly limited, and a known types of liquid crystal panel can be used. For example, TN, STN, VA, MVA, IPS, OCB, and the like can be given.

Next, the surface light source device 20 will be described.

The surface light source device 20 is arranged across the liquid crystal panel 15 from the observer side. The surface light source device 20 is a lighting device for emitting planar lights to the liquid crystal panel 15. As can be seen from FIGS. 1 and 2, in this embodiment, the surface light source device 20 is configured as an edge light type surface light source device, including a light guide plate 21, a light source 25, a light diffusion layer 26, a prism layer 27, a reflection type polarizing plate 28, an optical sheet 30, and a reflection sheet 39.

As can be seen from FIGS. 1 and 2, the light guiding plate 21 includes a base portion 22 and back face optical element 23. The light guiding plate 21 is a member formed in a plate shape as a whole, formed by a material having a light transmitting property. In this embodiment, one plate face side of the light guiding plate 21, which is on the observer side, is formed as a smooth face. The other plate face side which is on the opposite side of the observer side is formed as a back face, where a plurality of back face optical elements 23 are arranged.

As the materials of the base portion 22 and the back face optical elements 23, various materials can be used. Materials widely used as materials for optical sheets to be included in display devices, having excellent mechanical properties, optical properties, stability, and workability, and available at a low price can be used. For example, thermoplastic resins such as polymer resins having alicyclic structures, methacrylate resins, polycarbonate resins, polystyrene resins, acrylonitrile-styrene copolymers, methyl methacrylate-styrene copolymers, ABS resins, and polyether sulfone; and epoxy acrylate-based or urethane acrylate-based reactive resins (e.g. ionizing radiation curable resin) can be given.

The base portion 22 is a portion to be the base of the back face optical element 23, formed in a plate shape having a predetermined thickness, in which light is guided.

The back face optical element 23 is a projected element formed on the back face side (opposite side from the side where the reflection type polarizing plate 28 is to be arranged) of the base portion 22, and formed in a triangular column shape in this embodiment. The back face optical element 23 is formed in a column shape whose ridge line of the projected apex extends in the horizontal direction of the drawing sheet of FIG. 1. The plurality of back face optical elements 23 are arrayed having predetermined pitches, in the direction orthogonal to the direction where the ridge line extends. The cross section of the back face optical element 23 in this embodiment is shaped in a triangle. However, the present invention is not limited to this, and the cross section can be in any shapes such as a polygonal shape, hemispherical shape, a part of a sphere, and a lens shape.

It is preferable that the direction where the plurality of back face optical elements 23 are arrayed is the light guiding direction. That is, the back face optical elements 23 are arrayed in a separating direction from the light source 25, and the ridge line of each back face optical element 23 extends parallel to the direction where a plurality of light sources 25 are arranged, or, if the light source 25 is one long light source, a direction where the light source extends.

In this specification, “triangular shape” includes not only exact triangular shapes, but also shapes having errors in forming and limitations in manufacturing technique. Similarly, terms used in this specification to identify other shapes and geometric conditions, for example, “parallel”, “orthogonal”, “oval”, and “circle” is not limited to their exact meanings, but they shall be read including some degrees of errors with which similar optical functions can be expected.

The light guide plate 21 having the above-described structure can be manufactured by extrusion molding or by forming the back face element 23 on the base portion 22. As for the light guide plate 21 manufactured by extrusion molding, the base portion 22 and the back face optical element 23 may be integrally shaped. When the light guide plate 21 is manufactured by forming, the material of the back face optical element 23 may be same resin material as or not same as the material of the base portion 22.

Back to FIGS. 1 and 2, the light source 25 will be described. The light source 25 is arranged on one side of the side faces of the base portion 22 of the light guide plate 21, the side in the direction where the plurality of back face optical elements 23 are to be arrayed. The kind of the light source is not particularly limited, and the light source can be configured in various forms, for example, a fluorescent lamp such as a linear cold cathode tube, a point-like LED (light emitting diode), or an incandescent light bulb can be used. In this embodiment, the light source 25 is formed from a plurality of LEDs, and is configured such that the turning-on/off of each LED, and/or the brightness of each LED when turned on can be individually adjusted by a control device, which is not shown.

In this embodiment, one example where the light source 25 is arranged on one side face is shown. However, a structure where light sources are arranged on the opposite side face as well can also be taken. In that case, the shape of the back face optical element is formed according to known shapes.

Next, the light diffusion layer 26 will be described. The light diffusion layer 26 is a layer arranged on the light output side of the light guide plate 21, having a function to diffuse and emit the light entered the light guide plate 21. This increases more the uniformity of the light emitted from the light guide plate 21, which can make scars on the light guide plate 21 less distinct.

A known light diffusion layer can be used as a specific structure of the light diffusion layer. For example, a structure where a light diffusing agent is dispersed in a parent material can be given.

The prism layer 27 is, as can be seen from FIGS. 1 to 3, a layer arranged closer to the liquid crystal panel 15 than the light diffusion layer 26, including unit prism 27 a convex to the liquid crystal panel 15 side. The unit prism 27 a has a structure of extending in the light guiding direction of the light guide plate 21, having a predetermined cross section. In this embodiment, a plurality of unit prisms 27 a are arranged in a direction (in this embodiment, a direction orthogonal to the light guiding direction in a planar view) different from the light guiding direction.

A known shape can be applied to the cross-sectional shape of the unit prisms of the prism layer, depending on necessary functions. Light can be further diffused, or condensed, by the shape.

For example, the unit prism can be structured as follows. FIGS. 4, 5A and 5B show views for explanation.

FIG. 4 shows an example where the unit prism 27 a has a cross section formed in a pentagon prism shape.

FIG. 5A shows an example where a unit prism 27′a has a lenticular lens shape (convex cross section formed in a semicircular shape).

FIG. 5B shows an example where a unit prism 27″a has a concave cross section formed in a semicircular shape.

Next, the reflection type polarizing plate 28 will be described. The reflection type polarizing plate 28 has a function to: divide incident light into two polarization components (P wave and S wave) that are orthogonal to each other; transmit the polarization component (for example, P wave) of one direction (a direction parallel to a transmission axis); and absorb the polarization component (or example, S wave) of the other direction (a direction parallel to a reflection axis) which is orthogonal to the above direction. A known structure can be applied for the reflection type polarizing plate.

Here, the direction in which the transmission axis of the reflection type polarizing plate 28 extends is same as the direction in which the transmission axis of the above-described lower polarizing plate 14 extends, and can be at any angle of no more than 41.7° in a front view of the image source unit 1, to the direction in which the light transmissive portion 33 and the light absorbing portion 34 of the optical functional layer 32 described later extend. Preferably, this angle is 1° to 41.7°, more preferably 1° to 20°, and further preferably 1° to 5°. The angle of no more than 5° makes the viewing angle characteristics (balance between brightness and cutoff) especially good.

If this angle is no less than 0° and less than 1°, there is a high possibility that moire fringes form. Specifically, whiskers-like cut scraps easily form from the optical functional layer 32 in cutting because a side of an edge of the quadrilateral optical functional layer 32 is almost parallel to the direction where the light transmissive portion 33 and the light absorbing portion 34 extend.

Here, instead of the reflection type polarizing plate 28, the polarizing sheet 28′ explained here may be used. Similar to the reflection type polarizing plate 28, the polarizing sheet 28′ transmits the same polarized light as the polarized light that the lower polarizing plate transmits (for example, P wave), and reflects the other polarized light (for example, S wave). The structure of the polarizing sheet 28′ is shown enlarged in FIG. 6. As can be seen from FIG. 6, the polarizing sheet 28′ is formed from a transparent base material 28′, a transparent uneven layer 28′b on the transparent base material 28′a, and a metal thin film 28′c having a predetermined thickness layered on a surface of the transparent uneven layer 28′b.

The transparent base material 28′a is a sheet member formed in a flat plate for supporting the transparent uneven layer 28′b and the metal thin film 28′c.

As the material of the transparent base material 28′a, various materials may be used. Materials widely used as materials for optical sheets to be included in display devices, having excellent mechanical properties, optical properties, stability, and workability, and available at a low price may be used. For example, polyethylene terephthalate resins (PET), triacetylcellulose resins (TAC), methacrylic resins, polycarbonate resins and the like may be given. Among them, TAC, methacrylic resins, and polycarbonate which have less refraction are preferably used, considering the combination with the lower polarizing plate.

As for the transparent uneven layer 28′b, a unit convex portion 28′ba having a triangular shape at the cross section shown in FIG. 6 extends in a predetermined direction (direction orthogonal to the face of the drawing sheet of FIG. 6) along the face of the transparent base material 28′a, keeping the cross section. A plurality of unit convex portions 28′ba are arrayed in a direction orthogonal to the predetermined direction (direction in which the ridge line of each unit convex portion 28′ba extends).

As the material of the transparent uneven layer 28′b, for example ionizing radiation curable resins including ultraviolet curable resins such as epoxy acrylate based resin, urethane acrylate based resin, polyether acrylate based resin, polyester acrylate base resin, and polythiol acrylate based resin can be given.

The metal thin film 28′c is a layer formed from a thin film of metal such as aluminum, layered on the surface of the transparent uneven layer 28′b.

With this configuration, the polarizing sheet 28′ includes a face in triangular wave shape formed from metal, repeating at a predetermined pitch A. The triangular wave shape is an uneven face, formed from groove lines 28′ca repeating at the predetermined pitch A in the horizontal direction of the drawing sheet of FIG. 6 and ridge lines 28′cb. The triangular wave shape extends in the direction orthogonal to the drawing sheet of FIG. 6.

When random polarization (natural polarization) LR enters the polarizing sheet 28′ having the above structure, in a nearly vertical manner to the surface of the transparent base material 28′a, the component of linear polarization (S polarization) having an electric field vector, the vector oscillating parallel (direction orthogonal to the drawing sheet of FIG. 6) to the direction in which the groove lines 28′ca and the ridge lines 28′cb extend, emit polarization component in the same direction as the incident light, in order to oscillate electrons in the metal thin film 28′c, in a manner to be parallel to the groove lines 28′ca and the ridge lines 28′cb. As a result, the S polarization is reflected as reflection light LH (it is noted that the reflection light LH in FIG. 6 is an example of light path, which is conceptual). On the other hand, the component of linear polarization (P polarization) having an electric field vector, the vector oscillating in a direction (the arraying direction of the unit convex portions 28′ba, horizontal direction of the drawing sheet of FIG. 6) orthogonal to the extending direction of the groove lines 28′ca and the ridge lines 28′cb, the polarization component which cannot excite such oscillation of electrons, enters the metal thin film 28′c to reach the back face thereof and passes through the metal thin film 28′c as transmitted light LT. Then, when random polarization which is synthesized light of S polarization and P polarization enters the polarization sheet 28′, it is possible to separate the light into the S polarization of reflection light and the P polarization of transmitted light.

Here, the direction in which the transmission axis of the polarizing sheet 28′ extends (that is, the direction orthogonal to the direction in which the groove lines 28′ca and the ridge lines 28′cb extend, the direction in which the groove lines 28′ca and the ridge lines 28′ cb are alternately arrayed) is same as the direction in which the transmission axis of the lower polarizing plate 14 extends, and can be at any angle of no more than 41.7° in the front view of the image source unit 10, to the direction in which the light transmissive portion 33 and the light absorbing portion 34 of the optical functional layer 32 described later extend. Preferably, this angle is 1° to 41.7°, more preferably 1° to 20°, and further preferably 1° to 5°. The angle of no more than 5° makes the viewing angle characteristics (balance between brightness and cutoff) especially good.

If this angle is no less than 0° and less than 1°, there is a high possibility that moire fringes form. Specifically, whiskers-like cut scraps easily form from the optical functional layer 32 in cutting because a side of an edge of the quadrilateral optical functional layer 32 is almost parallel to the direction where the light transmissive portion 33 and the light absorbing portion 34 extend.

The polarizing sheet 28′ preferably satisfies the following conditions. This makes it possible to efficiently divide light into S polarization and P polarization.

The interval (constant pitch) A (μm) between the adjacent groove lines 28′ca is preferably no more than 1 μm, and more preferably in the range of from 0.1 μm to 0.2 μm. The height h (μm) of the ridge line 28′cb to the groove line 28′ca is preferably no more than 1 μm, and more preferably in the range of from 0.2 μm to 0.4 μm. The thickness of the metal thin film 28′c in the direction vertical to the transparent material 28′a (thickness direction of the transparent base material 28′a) is preferably no less than 0.01 μm. If the thickness d of the metal thin film 28′c is thinner than 0.01 μm, the transmittance of S polarization gets large, whereby the extinction ratio degrades. Even if the thickness gets large, the thickness in the direction vertical to the oblique face of the projection of the metal thin film 28′c can be thin by making the height h to the pitch A large. Therefore, it is possible to provide a good extinction ratio of S polarization and P polarization. As such, the upper limit of the thickness of the metal thin film 28′c may not be set.

As the metal material which may be used for the metal thin film 28′c, aluminum (Al) whose extinction coefficient is approximately 5, and according to this, gold (Au) and silver (Ag) are suitable as well.

Here, shown is an example in which the cross section of the unit convex portion 28′ba is triangle and therefore the cross section of the metal thin film 28′c is also triangle. However, the cross-sectional shape is not limited to this, and may be a rectangular shape, and may be in a shape including a carved line in a part or as a whole, such as semicircular and semi-elliptical shape.

The polarizing sheet 28′ may be produced as follows for example. That is, firstly, an original plate is made. The original plate is a mold, on the surface of which the unevenness corresponding to the transparent uneven layer 28′b is formed. This unevenness may be formed by nano/micro cutting, lithography, two-luminous-flux interference exposure method and the like.

Next, a layered body in which an uncured ultraviolet curable resin is applied on one surface of the transparent base material 28′a is prepared. The ultraviolet curable resin side is pressed to the original plate, cured by ultraviolet, and removed from the original plate.

Then, aluminum is evaporated to the cured ultraviolet curable resin by vacuum vapor deposition.

As described above, the polarizing sheet 28′ has a simple structure, and therefore the sheet may be manufactured easier than conventional reflection type polarizing plates.

Next, the optical sheet 30 will be described. As is seen from FIGS. 1 to 3, the optical sheet 30 includes a base material layer 31 formed in a sheet shape, an optical functional layer 32 arranged on one surface of the base material layer 31 (in this embodiment, the face on the light guide plate 21 side), and an adhesive layer 35 arranged on the other side (face on the liquid crystal panel 15 side) of the base material layer 31.

As described later, this optical sheet 30 has a function (light condensing function) of changing the traveling directions of the light incident from the light input side to emit the light from the light output side, and intensively increasing the brightness in the front direction (normal direction). At this time, variations of the polarization component are inhibited, whereby it is possible to increase the use efficiency of light by these functions. Further, the optical sheet 30 has a function of absorbing light traveled having a large angle to the front direction (light absorbing function).

As shown in FIGS. 1 to 3, the base material layer 31 is a plate-like translucent member formed in a sheet, supporting the optical functional sheet 32 and the adhesive layer 35. FIG. 7 shows an enlarged view of a part of the optical sheet 30 in FIG. 2.

As the material of the base material layer 31, various materials may be used. Materials widely used as materials for optical sheets to be included in display devices, having excellent mechanical properties, optical properties, stability, workability and the like, and available at low costs may be preferably used. Examples thereof include polyethylene terephthalate resin (PET), triacetylcellulose resin (TAC), methacrylic resin, polycarbonate resin, and the like.

The retardation of the base material layer 31 is preferably small. Specifically, the front retardation when the wavelength is 590 nm is preferably no more than 15 nm. This makes it possible to transmit light through the lower polarizing plate without disturbing the state of polarization that has been arranged at the reflection type polarizing plate, to reduce the amount of the light absorbed by the lower polarizing plate, and to improve the use efficiency of the light. In view of this, among the above described materials that may be used for the base material layer 31, triacetylcellulose resin, methacrylic resin, and polycarbonate resin are preferably used. Further, for purposes that require a high heat resistance property such as on-vehicle use, polycarbonate resin which has a high glass transition point is desirable. Specifically, the glass transition point of polycarbonate resin is 143° C., which is suitable for on-vehicle use generally requiring durability at 105° C.

Further, an optical axis (slow axis) of the base material layer is desirably parallel to or perpendicular to the extending direction of the light absorbing portions in the front view. This makes it possible to suppress change in the state of polarization of the polarized light entering the optical sheet 30.

Whereby, degradation of the quality of the image due to occurrence of crinkles to the laminate can be suppressed, and sounds emitted by the laminate shaking in the housing and hitting the interior surface of the housing etc. can be suppressed even if the base material layer expands and/or contracts due to some environmental change.

The thickness of the base material layer 31 is not particularly limited, and preferably in the range of from 25 μm to 300 μm. If the thickness of the base material layer 31 is out of the range, problems may cause in workability. For example, if the base material layer 31 is thinner than 25 μm, crinkles may easily occur, and if the base material layer is thicker than 300 μm, rolling up of the optical sheet 30 may get difficult.

As is seen from FIGS. 2, 3 and 7, a rough face 31 a may be formed on a face of the base material layer 31, the face being the opposite side from the face where the optical functional layer 32 is layered (that is, the face where the adhesive layer 35 is to be arranged). As described later, the rough face 31 a functions as a light diffuser with the refractive index difference between the adhesive layer 35 and the base material layer 31, which makes it possible to suppress occurrence of moire interference fringes. The degree of the surface roughness of the rough face 31 a is not particularly limited, and preferably no less than 0.1 μm in average roughness (Ra) because the above-described effect to be obtained by the formation of the rough face gets small if the degree of the surface roughness is too small. In contrast, in view of increase of light diffusion and reduction of the effect of controlling the light emitting range, the Ra is preferably no more than 1.5 μm.

A known method can be applied to the method for forming the rough face 31 a. Examples thereof include transcriptions by a roll where embosses are formed, sandblast, printing, and coating.

The optical functional layer 32 is a layer laminated on one surface (in this embodiment, the surface on the light guide plate 21 side) of the base material layer 31, on which the light transmissive portions 33 and the light absorbing portions 34 are alternately arrayed along the layer face.

The optical functional layer 32 has a shape extending from the back to the surface of the drawing sheet having the cross section shown in FIG. 7. That is, at the cross section shown in FIG. 7, the optical functional layer 32 includes the light transmissive portions 33 each having an approximately trapezoidal shape, and the light absorbing portions 34 each formed between two adjacent light transmissive portions 33, whose cross sections are each an approximately trapezoidal shape.

Here, as conceptually shown in FIG. 8, an angle θ_(s) formed by: the extending direction of the light transmissive portions 33 and the light absorbing portions 34, shown by a solid line VIa; and the extending direction of the transmission axis of the lower polarizing plate 14, shown by a dotted line VIb, is no more than 41.7°, preferably is 1° to 41.7° when the image source unit 1 is seen from the front direction on the observer side. This makes it possible to inhibit the variation of the polarization component by the reflection at the interfaces between the light transmissive portions 33 and the light absorbing portions 34, and to improve the transmittance ratio.

It is more preferable that θ_(s) be 1° to 20°. By having θ_(s) in this range, the variation of the transmittance ratio by the variation of θ_(s) gets small, which can reduce the variation of performance caused from the variation of θ_(s) in manufacturing, which makes it possible to provide an optical functional layer having a stable performance.

Most preferably, θ_(s) is 1° to 5°. The angle of no more than 5° makes the viewing angle characteristics (balance between brightness and cutoff) especially good.

If θ_(s) is no less than 0° and less than 1°, there is a high possibility that moire fringes form. Specifically, in view of manufacturing, whiskers-like cut scraps easily form from the optical functional layer 32 in cutting because a side of an edge of the quadrilateral optical functional layer 32 is almost parallel to the direction where the light transmissive portion 33 and the light absorbing portion 34 extend.

If this angle θ_(s) is 90°, the light reflected on the interface between the light transmissive portion and the light absorbing portion at this time is a polarized light along the absorption axis of the lower polarizing plate, which brings some fault of being absorbed.

The light transmissive portion 33 is a portion whose main function is to transmit light. In this embodiment, the light transmissive portion 33 is an element having an approximately trapezoidal cross-sectional shape at the cross section shown in FIGS. 2 and 7, the approximately trapezoidal cross-sectional shape having a longer lower base on the base material layer 31 side and a shorter upper base on the other side (light guide plate side). The light transmissive portions 33 extend in the above-described direction, keeping the cross sections along the layer face of the base material layer 31, and are arrayed having predetermined intervals in a different direction from the extending direction. Between adjacent light transmissive portions 33, an interval having an approximately trapezoidal cross section is formed. Therefore, the interval has a trapezoidal cross section having a longer lower base on the upper base side (light guide plate 21 side) of the light transmissive portion 33 and a shorter upper base on the lower base side (liquid crystal panel side) of the light transmissive portion 33. The light absorbing portion 34 is formed from a necessary material described later filled in the interval. In this embodiment, the adjacent light transmissive portions 33 are connected by a sill portion 32 a at the longer lower base side.

The refractive index of the light transmissive portion 33 is made to be Nt. Such a light transmissive portion 33 may be formed by curing of a composition constituting the light transmissive portion. Details will be described later. The value of the refractive index Nt is not particularly limited, and preferably no less than 1.55 in view of properly reflecting light (including total reflection) at the interfaces between the light transmissive portions 33 and the light absorbing portions 34 at the oblique faces of the trapezoidal cross sections, which is described later. However, the refractive index is preferably no more than 1.61, because materials having too high refractive indexes tend to easily crack. More preferably, the index is no more than 1.56.

The light absorbing portion 34 functions as an in-between portion formed in the above-described interval formed between adjacent light transmissive portions 33, and has a similar cross-sectional shape as that of the interval. Therefore, a shorter upper base faces the liquid crystal panel 15 side, and the longer lower base is on the light guide plate 21 side. The light absorbing portion 34 is formed in a manner that its refractive index is Nr and it can absorb light. Specifically, light absorbing particles are dispersed in a binder whose refractive index is Nr. The refractive index Nr is lower than the refractive index Nt of the light transmissive portion 33. By making the refractive index of the light absorbing portion 34 smaller than the refractive index of the light transmissive portion 33 as described above, it is possible to totally reflect the light entered the light transmissive portion 33 under predetermined conditions, properly at the interface between the light transmissive portion 33 and the light absorbing portion 34. Even if the conditions of total reflection are not satisfied, part of light is reflected at the interface.

The value of the refractive index Nr is not particularly limited, and preferably no more than 1.50 in view of properly making the total reflection. In the range, in view of availability, no less than 1.47 is preferable. More preferably it is no less than 1.49.

The difference between the refractive index Nt of the light transmissive portion 33 and the refractive index Nr of the light absorbing portion 34 is not particularly limited, and preferably in the range of from 0.05 to 0.14. By having a large refractive index difference, much light can be totally reflected.

Of the optical functional layer 32, though not particularly limited, the light transmissive portion 33 and the light absorbing portion 34 are formed in the following manner for example. That is, the pitch of the light transmissive portion 33 and the light absorbing portion 34, shown by P_(k) in FIG. 7 is preferably in the range of from 20 μm to 100 μm. In addition, the angle formed by: the interface between the light absorbing portion 34 and the light transmissive portion 33 at an oblique side; and the normal line of the layer face of the optical functional layer 32, shown by θ_(k) in FIG. 7, is preferably in the range of from 1° to 10°. The thickness of the light absorbing portion 34 shown by D_(k) in FIG. 7 is preferably in the range of from 50 μm to 150 μm. Within these ranges, a proper balance of the transmission and absorption of light is obtained in many cases.

In this embodiment, shown is an example in which the interface between the light transmissive portion 33 and the light absorbing portion 34 is in a straight line shape at the cross section. However, the shape is not limited to a straight line, and may by in a polygonal line shape, in a convex curved surface shape and in a concave curved surface shape. The cross-sectional shapes of plurality of light transmissive portions 33 and the light absorbing portion 34 may be the same, and may be different having a predetermined regularity.

The adhesive layer 35 is a layer to attach the optical sheet 30 to the lower polarizing plate 14 by adhesion, and layer the optical sheet and the liquid crystal panel 15 (lower polarizing plate 14) without forming air interfaces between them. This makes it possible to improve the transmittance of light and increase the use efficiency of light. The attaching with adhesion creates no friction between the layers, which can prevent damages.

The material for the adhesive layer 35 is not particularly limited, and known adhesives, glues, photocurable resins, thermosetting resins, and the like may be used. As a more specific example, an acrylic adhesive may be used as the adhesive layer 35, and as a further specific example, a combined adhesive of an acrylic copolymer and an isocyanate compound may be given. However, the material for the adhesive layer 35 is preferably a material having good light transmissive property and weatherability, considering the nature of the optical sheet 30.

The thickness of the adhesive layer 35 is not particularly limited, and preferably in the range of from 25 μm to 50 μm. If the adhesive layer 35 is thinner than 25 μm, moires get easier to occur. If the thickness of the adhesive layer 35 is thicker than 50 μm, it gets difficult to roll up of the optical sheet 30, and dirt by protrusion of the adhesive from edges gets easily occur.

Here, it is preferable that the base material layer 31 and the adhesive layer 35 have a refractive index difference. This makes it possible to form a light diffuser by the rough face 31 a and the refractive index difference, and to prevent occurrence of moire interference fringes. As a cause of the moire interference fringes, given is the interference fringe of the stripe pattern of the light absorbing portion 34 and the regular pattern of the pixels of the liquid crystal panel 15. Therefore, according to this embodiment, it is possible to inhibit degradation of the quality of the screen by the occurrence of such moire interference fringes.

The degree of the refractive index difference is not particularly limited, and preferably in the range of from 0.02 to 0.2. If the difference is less than 0.02, the effect of preventing moire interference fringes get small, and if the difference is more than 0.2, the effect of controlling light at the optical functional layer 32 may degrade and it may get difficult to obtain the material. The refractive index of the base material 31 may be larger than that of the adhesive layer 35, and the refractive index of the adhesive layer 35 may be larger than that of the base material layer 31.

According to the examination by the inventor, moire interference fringes did not occur when a polycarbonate of 130 μm in thickness and of 1.585 in refractive index was used as the base material layer 31, and an adhesive of 1.490 in refractive index (acrylic adhesive, PANACLEAN (registered trademark) PD-S1, manufactured by Panac Co., Ltd.) was used for forming an adhesive layer of 25 μm in thickness. Even under the environment of 95° C. for 1000 hours, peeling did not occur.

On the other hand, when an optical sheet was formed including an adhesive layer (acrylic adhesive, PANACLEAN (registered trademark) PD-S1 manufactured by Panac Co., Ltd., refractive index: 1.490) of 25 μm in thickness including a base material layer formed from polycarbonate (thickness: 130 μm, refractive index: 1.585) not having a rough face and light diffusing agent (acrylic styrene particles of 4 μm in average particle diameter and of 1.520 in refractive index) dispersed in the base material layer, it was possible to reduce moire interference fringes. Therefore, the light diffuser may be made also from an adhesive layer in which a light diffusing material is dispersed. As such, as a variation example, an adhesive layer in which a light diffusing material is dispersed may be layered on a base material not having a rough face.

In this example, however, the adhesive power tends to degrade.

As described above, in this invention, a light diffuser is provided between the optical functional layer 32 and the lower polarizing plate 14 where the optical sheet 30 is to be attached.

The optical sheet 30 is produced in the following manner for example.

First, the light transmissive portions 33 are formed on a face of the base material layer 31, the face where the rough face 31 a is not formed. That is, a base material sheet to become the base material layer 31 is inserted in between a die roll having on its surface a shape that can transfer the shape of the light transmissive portions 33, and a nip roll arranged in a manner facing the die roll. At this time, the die roll and the nip roll are rotated while a composition for constituting the light transmissive portions is supplied in between the base material sheet and the die roll. Whereby, the composition for constituting the light transmissive portion is filled in grooves (a reversed shape of the light transmissive portions) formed on the surface of the die roll, which grooves corresponds to the light transmissive portions, and accordingly the composition becomes the surface shape of the die roll.

Here, as for the composition for constituting the light transmissive portions, ionizing radiation-curable resins such as epoxy acrylate-based, urethane acrylate-based, polyether acrylate-based, polyester acrylate-based, polythiol-based resins may be used.

The composition for constituting the light transmissive portions sandwiched between the die roll and the base material sheet and filled therein is irradiated with a light for curing, from the base material sheet side by a light irradiation apparatus. Whereby, the resin can be cured and the shape thereof can be fixed. Then, the base material layer 31 and the molded light transmissive portions 33 are released from the die roll by a mold release roll.

Next, the light absorbing portion 34 is formed. First, a composition for constituting the light absorbing portion is filled in a gap between the above formed light transmissive portions 33. Thereafter, the excessive amount of composition is scraped off by a doctor blade or the like. Then, the remaining composition is cured by an irradiation of light for curing from the light transmissive portion 33 side; and as a result, the light absorbing portion 34 can be formed.

The material to be used as the light absorbing portion is not particularly limited, and for example, a composition in which colored light absorbing particles are dispersed in a photocurable resin such as urethane(meth)acrylate, polyester(meth)acrylate, epoxy(meth)acrylate, and butadiene(meth)acrylate may be used.

Instead of dispersing the light absorbing particles, the whole light absorbing portion may be colored by a pigment or dye.

When the light absorbing particles are used, colored particles having a light absorbing property such as carbon black are preferably used. However, the light absorbing particles are not limited thereto. Colored particles which selectively absorb light with a certain wavelength in accordance with the properties of the image light may be employed. Specific examples include: carbon black, graphite, metal salts of black iron oxide and the like, organic particulates or glass beads colored by dye, pigment, and the like. Especially, the colored organic particulates are preferably used in view of costs, quality, availability, and the like. The average particle size of the colored particles is preferably in the range of from 1.0 μm to 20 μm.

Then, the adhesive layer 35 is formed by coating and the like, on a face of the base material layer 31, the face where the rough face 31 a is formed. The rough face 31 a may be directly provided for the base material layer 31 in advance, or a layer having the rough face 31 a may be layered on the base material layer 31 in advance.

In this manner, the optical sheet 30 is formed in which the optical functional layer 32 is layered on one face of the base material layer 31 and the adhesive layer 35 is layered on the other face where the rough face 31 a is formed.

As shown in FIG. 9, a layer 31′ that forms a rough face may be provided over one side of the optical functional layer 32 which is opposite to the side where the base material layer 31 is layered, which makes it possible to further suppress occurrence of moire interference fringe. The degree of the surface roughness of this layer 31′ is not particularly limited, and preferably no less than 0.1 μm in average roughness (Ra) because the above-described effect to be obtained by the formation of the rough face gets small if the degree of the surface roughness is too small. In contrast, in view of increase of light diffusion and reduction of the effect of controlling the light emitting range, the Ra is preferably no more than 1.5 μm.

Material constituting this layer 31′ can be considered in the same manner as that of the base material 31.

In the laminate including at least the base material made from polycarbonate and the optical functional layer, the mean value of the coefficient of linear expansion within the range of −50° C. and 130° C. can be 0 (1/° C.) to 1×10⁻⁴ (1/° C.).

When this coefficient of linear expansion is a, the mean value of the expansion within the range of −50° C. and 130° C., which is represented by αΔT×100% can be 0% to 2%.

Here, the coefficients of linear expansion may be different in the optical functional layer between the extending direction of the light transmissive portions and the light absorbing portion, and the direction where they are arranged. In this case, the laminate can be configured so that the mean value of the coefficients of linear expansion of the light transmissive portion and the light absorbing portion, and the mean value of the expansions thereof satisfy the above conditions.

The laminate can be configured so that the above conditions are satisfied as well when the adhesive layer and the polarizing plates are layered in addition to the base material layer and the optical functional layer.

Back to FIGS. 1 to 3, the reflection sheet 39 of the surface light source device 20 will be described. The reflection sheet 39 is a member for reflecting the light emitted from the back face of the light guide plate 21 to make the light enter the light guide plate 21 again. As for the reflection sheet 39, a sheet that enables so-called specular reflection may be preferably employed, for example a sheet made of a material having high reflectance such as metal, or a sheet that includes as a surface layer, a thin film made of a material having high reflectance (for example, thin metal film).

The functional film 40 is a layer arranged on the light output side of the liquid crystal panel 15, having functions to improve the quality of image light, protect the image source unit 10, and the like. Example thereof include anti-reflection films, anti-glare films, hard coating films, color compensation films, light diffuser films and the like. These films are used alone or in combination to form the functional film 40.

Next, the functions of the display device having the above structure will be described showing examples of light paths. It is noted that the examples of the light paths are conceptualistic for explanation, not strictly showing the degrees of reflection and refraction.

First, the light emitted from the light source 25 enters the light guide plate 21 through the light input face on the side face of the light guide plate 21, as shown in FIG. 2. FIG. 2 shows, as one example, light paths of the lights L21 and L22 incident upon the light guide plate 21 from the light source 25.

As shown in FIG. 2, the lights L21 and L22 that have entered the light guide plate 21 repeat total reflection on the face on the light output side of the light guide plate 21 and the back face opposite thereto, due to the refractive index difference from the air; and travel in the light guiding direction (to the right of the drawing sheet of FIG. 2).

Here, the back face optical element 23 is arranged on the back face of the light guide plate 21. Therefore, as shown in FIG. 2, in some cases, the traveling directions of the lights L21 and L22 travelling through the light guide plate 21 are changed by the back face optical element 23, and thus the lights L21 and L22 enter the light output face and the face opposite thereto at an incident angle of less than a total reflection critical angle. In this case, the light may be emitted from the light output face and the face opposite thereto of the light guide plate 21.

The lights L21 and L22 emitted from the light output face travel to the reflection type polarizing plate 28 arranged on the light output side of the light guide plate 21. On the other hand, the light emitted from the back face is reflected by the reflection sheet 39 arranged on the rear face of the light guide plate 21; and enters again the light guide plate 21 to travel through the light guide plate 21.

The light travelling through the light guide plate 21 and the light that changed its direction at the back face optical element 23 and reaches the light output face having an incident angle less than a total reflection critical angle are created in each zone along the light guiding direction of the light guide plate 21. Therefore, the light travelling through the light guide plate 21 is emitted from the light output face little by little. This enables a uniform light amount distribution, along the light guiding direction of the light emitted from the light output face of the light guide plate 21.

The light emitted from the light guide plate 21 reaches the light diffuser layer 26 to increase its uniformity. Then, the light is diffused or collected as necessary by the prism layer 27, and emitted from the prism layer 27. The emitted light reaches next the reflection type polarizing plate 28. Here, the light in the polarizing direction along the transmission axis of the reflection type polarizing plate 28 transmits through the reflection type polarizing plate 28 and travels to the optical sheet 30.

On the other hand, the light in the polarizing direction along the reflection axis of the reflection type polarizing plate 28 is reflected and returns to the light guide plate 21 side, as shown by arrows of dotted lines L21′ and L22′ in FIG. 2. The returned light is reflected at the light guide plate 21, the back face optical element 23, or the reflection sheet 39, and travels again in the reflection type polarizing plate 28 side. In this reflection, part of the light changes its polarizing direction and passes through the reflection type polarizing plate 28. Other light returns again to the light guide plate side. In this way, by repeating the reflection, the light reflected at the reflection type polarizing plate 28 also can pass through the reflection type polarizing plate 28. This makes it possible to increase the use efficiency of the light from the light source 25.

Here, the light emitted from the reflection type polarizing plate 28, whose polarizing direction is a direction along the transmission axis of the lower polarizing plate 14, is a polarized light which passes through the lower polarizing plate 14.

The light emitted from the reflection type polarizing plate 28 enters the optical functional layer 32. The light which enters the optical functional layer 32, which is polarized light that passes through the lower polarizing plate 14, travels having the following light path. That is, as shown by L51 in FIG. 7 for example, the light passes through the light transmissive portion 33 without reaching the interface between the light transmissive portion 33 and the light absorbing portion 34. Or, as shown by L52 in FIG. 7, the light reaches the interface between the light transmissive portion 33 and the light absorbing portion 34 and is totally reflected to pass through the light transmissive portion 33. At this time, in this embodiment, the light reflected at the interface is made closer to the direction parallel to the normal line of the liquid crystal panel 15, by the function of the inclination angle (θ_(k)) of the interface. In addition, even in light that is not totally reflected because it has a smaller angle than the critical angle of total reflection, part of the light is reflected at the interface. This kind of light also passes through the light transmissive portion 33.

This makes it possible to effectively provide, to the liquid crystal panel 15, light that does not cause defects such as deterioration of contrast and color inversion when the light passes through the liquid crystal panel 15. Further, the extending direction of the light transmissive portion 33 and the light absorbing portion 34 has an angle of no more than 41.7°, preferably 1° to 41.7°, and more preferably 1° to 20° in the front view, to the extending direction of the transmission axis of the lower polarizing plate 14. Therefore it is possible to inhibit the change of the polarization direction when the light is reflected or totally reflected at the interface. As such, it is possible to make a lot of light, which is totally reflected or reflected at the interface, pass through the lower polarizing plate 14. Therefore, it is possible to improve the use efficiency of light (light transmittance).

On the other hand, the light entered the optical functional layer 32 having a large angle to the normal line of the sheet face, is absorbed by the light absorbing portion 34, therefore the light is not provided to the liquid crystal panel 15. As such, it is possible to absorb light that causes defects such as contrast degradation and color inversion.

According to the optical sheet 30, it is possible to efficiently collect light from the light guide plate 21, and light that is not collected is absorbed by the light absorbing portion. Therefore it is possible to efficiently provide proper light to the liquid crystal panel, and to greatly improve the use efficiency of light. In addition, according to the optical sheet 30, it is possible to keep the polarizing direction of the light which is to be transmitted through the lower polarizing plate 14, when the light is provided to the lower polarizing plate 14. Therefore it is possible to inhibit light to be absorbed by the lower polarizing plate 14 and improve the use efficiency (transmittance) of light.

Light paths will be further explained. The light emitted from the surface light source device 20 as described above enters the lower polarizing plate 14 of the liquid crystal panel 15. The light passed through the optical functional layer 32 enters the lower polarizing plate 14 of the liquid crystal panel 15 via the adhesive layer 35, without going through any air layers. In this manner, in this embodiment, by having the adhesive layer 35, it is possible to make light directly enter the liquid crystal panel 15 without going through air interfaces. Therefore it is possible to inhibit light loss and to improve the use efficiency.

Of the incident light, the lower polarizing plate 14 transmits one of the polarization components and absorbs the other polarization component. The light transmitted through the lower polarizing plate 14 is selectively passes through the upper polarizing plate 13 in accordance with the state of the application of the electric field on each pixel. In this manner, the liquid crystal panel 15 selectively transmits the light from the surface light source device 20 on a pixel to pixel basis, thereby enabling the observer of the liquid crystal display device to observe the image. At this time, the image light is provided to the observer via the functional film 40, therefore the quality of image is improved.

In addition, in this embodiment, the rough face 31 a is provided on the base material layer 31 of the optical functional layer 32, and there is a difference in the refractive index between the rough face 31 a and the adhesive layer 35 layered on the rough face 31 a. This makes it possible to prevent the occurrence of moire interference fringe and to obtain a high quality display.

An example in which the optical sheet 30 and the liquid crystal panel 15 are attached to each other by the adhesive layer 35 is shown above. Regarding other layers, they may be arranged having air layers therebetween as necessary, or they may be attached to one another by adhesive agents, or may be arranged to have contact with one another without having adhesive agents.

FIG. 10 is a view to explain a second embodiment, corresponding to FIG. 7. In this embodiment, an optical sheet 130 is applied instead of the optical sheet 30, and other structure is same as the above image source unit 10.

The optical sheet 130 includes the base material layer 31 like the optical sheet 30. However it has an optical functional layer 132 instead of the optical functional layer 32, which is a different point from the optical sheet 30. Specifically, in this embodiment, an in-between portion 134 arranged between the adjacent light transmissive portions 33 has a light reflection layer 134 a at the interface with the light transmissive portion 33. In the in-between portion 134, a light absorbing portion 134 b is formed at a portion between the light reflection layers 134 a.

The light reflection layer 134 a is a layer to reflect light, using reflection of the surface of metal or other materials, and formed in the in-between portion 134, at the interface between the in-between portion 134 and the light transmissive portion 33. The light reflection layer 134 a may be formed by a vapor deposition film of aluminum, copper, silver, and the like.

The light absorbing portion 134 b may be formed as in forming the above-described light absorbing portion 34.

According to such an optical functional layer 132, for example the light shown by L71 in FIG. 10 passes through the light transmissive portion 33 without reaching the interface between the light transmissive portion 33 and the in-between portion 134. Or, the light shown by L72 in FIG. 10 is reflected at the light reflection layer 134 a even if the light reaches the interface between the light transmissive portion 33 and the in-between portion 134, and the light passes through the light transmissive portion 33. In this embodiment, the reflection is not by a total reflection. Therefore even light which does not satisfy the conditions of total reflection can be reflected at the light reflection layer 134 a to be emitted. This makes it possible to emit more bright light.

FIG. 11 is a view to explain a third embodiment, corresponding to FIG. 7. In this embodiment, an optical sheet 230 is applied instead of the optical sheet 30, and other structure is same as that of the image source unit 10.

The optical sheet 230 includes the base material layer 31 like the optical sheet 30. However, the optical sheet 230 includes an optical functional layer 232 instead of the optical functional layer 32, which is a different point from the optical sheet 30. Specifically, an in-between portion 234 arranged between the adjacent light transmissive portions 33 includes a light reflection layer 234 a at the interface with the light transmissive portion 33. In the in-between portion 234, a transparent portion 234 b is formed in a portion between the light reflection layers 234 a.

The light reflection layer 234 a is a layer to reflect light, using reflection of the surface of metal or other materials, and formed in the in-between portion 234, at the interface between the in-between portion 234 and the light transmissive portion 33. The light reflection layer 234 a may be formed by a vapor deposition film of aluminum, copper, silver, and the like.

The transparent portion 234 b may be formed by a hollow, or may be filled with a transparent resin, to transmit light.

According to such an optical functional layer 232, for example the light shown by L81 in FIG. 11 is transmitted through the light transmissive portion 33 without reaching the interface between the light transmissive portion 33 and the in-between portion 234. Or, the light shown by L82 in FIG. 11 is reflected at the light reflection layer 234 a even if the light reaches the interface between the light transmissive portion 33 and the in-between portion 234, and the light is transmitted through the light transmissive portion 33. In this embodiment, the reflection is not by a total reflection. Therefore even light which does not satisfy the conditions of total reflection can be reflected at the light reflection layer 234 a to be emitted. This makes it possible to emit more bright light.

Further, in the optical functional layer 232, the light entered the transparent portion 234 b of the in-between portion 234 from the light input face side (the lower side of the drawing sheet of FIG. 11) is repeatedly reflected inside the in-between portion 234 (L83), and sent back to the light input face side. The returned light is reflected at other portions and returns again to the optical functional layer, to be used again. Therefore it is possible to provide further bright light.

FIG. 12 is a view showing a fourth embodiment, and is a perspective view of an image source unit 310. FIG. 12 corresponds to FIG. 1. The image source unit 310 is different from the image source unit 10 in that a prism layer 327 is arranged in the surface light source device 320 instead of the prism layer 27 in the surface light source device 20 included in the image source unit 10. The other structure is the same as the description above.

The prism layer 327 is, as can be seen from FIG. 12, arranged closer to the liquid crystal panel 15 than the light diffusion layer 26, including unit prisms 327 a convex to the liquid crystal panel 15 side. Each unit prism 327 a has a structure of extending in parallel to the direction where the light transmissive portions 33 and the light absorbing portions 34 of the optical functional layer 32 extend, having a predetermined cross section. The unit prisms 327 a are arranged in a direction same as the direction where the light transmissive portions 33 are arranged.

A known shape can be applied to the cross-sectional shape of the unit prisms of the prism layer, depending on necessary functions. Light can be further diffused, or condensed, by the shape.

The optical functional layer 32, because of its nature, absorbs most of light that travels in the direction where the light transmissive portions 33 and the light absorbing portions 34 are alternately arranged, which easily reaches the interface between the light transmissive portions 33 and the light absorbing portions 34, and transmits most of light that travels in the direction where the light transmissive portions 33 extend, which is difficult to reach the interface between the light transmissive portions 33 and the light absorbing portions 34.

In contrast, the prism layer 327 can change the direction of light travelling in the direction where the unit prisms 327 a are arranged (the light is directed in the direction of approaching the front in the case of condensation).

Thus, when the prism layer 327 is configured as an optical element that condenses light, the amount of light absorbed by the light absorbing portions 34, the light having been emitted from the prism payer 327, can be reduced and the use efficiency of the light can be improved by making the direction where the light transmissive portions 33 and the light absorbing portions 34 of the optical functional layer 32 extend parallel to the direction where the unit prisms 327 a extend (making the direction where the light transmissive portions 33 and the light absorbing portions 34 are alternately arranged parallel to the direction where the unit prisms 327 a are arranged).

As Examination Examples, the relationship between θ_(s) (°) and the transmittance (%) shown in FIG. 8 was obtained in simulation.

Examination Example 1

As Examination Example 1, the simulation was carried out on an image source unit corresponding to the image source unit 10 explained with reference to FIG. 1. One example of the structure of unit is as follows.

<Base Material Layer>

Thickness: 130 μm

<Optical Functional Layer>

Pitch: 39 μm (P_(k) in FIG. 7)

Width of upper base of light absorbing portion: 4 μm (W_(a) in FIG. 7)

Width of lower base of light absorbing portion: 10 μm (W_(b) in FIG. 7)

Thickness of light absorbing portion: 102 μm (see D_(k) in FIG. 7)

Thickness of optical functional layer: 127 μm

Material and refractive index of light transmissive portion: ultraviolet curable urethane acrylate; refractive index 1.56

Material and refractive index of light absorbing portion: carbon black-containing acrylic beads-dispersed ultraviolet curable urethane acrylate having a refractive index of 1.49, where 25 mass % of acrylic beads is dispersed in 100 mass % of the urethane acrylate

<Liquid Crystal Panel, Reflection Type Polarizing Plate, Light Guide Plate and Light Source>

A liquid crystal panel, reflection type polarizing plate, light guide plate and light source provided to a 6.5 inch liquid crystal display device (LQ065T5GG03, manufactured by SHARP CORPORATION) were used.

The results are shown in Table 1 and FIG. 13. In Table 1 and FIG. 13, the transmittance ratio T_(p) is calculated from T _(p)=(T ₁ /T ₀)·100(%) wherein a value of transmittance T₁ at intended θ_(s) is expressed in percentage, setting the transmittance ratio T₀ where θ_(s)=90° as 100%. In FIG. 13, θ_(s) is taken along the horizontal axis and the transmittance ratio T_(p) is taken along the vertical axis.

TABLE 1 θ_(s) (°) T_(p) (%) 0 101.18 10 101.15 20 101.05 30 100.91 40 100.72 45 100.62 50 100.52 60 100.32 70 100.15 80 100.04 90 100.00

Based on the results, the obtained approximate formula is the formula (1) by a least-square method. T _(p)=(4×10⁻⁸)·θ_(s) ³−(5×10⁻⁶)·θ_(s) ²+(3λ10⁻⁵)·θ_(s)+1.0117  (1)

According to this, it is possible to make the transmittance ratio T_(p) large by making θ_(s) smaller than 90°. However, in view of making the transmittance ratio more effectively large, preferably θ_(s) is smaller than the inflection point of the formula (1), which is, 0°≤θ_(s)≤41.7°. Further, as is seen from FIG. 13, when θ_(s) is in the range of no more than 20°, the variation of the transmittance ratio T_(p) is small compared to the variation of θ_(s), therefore it is possible to inhibit variation in the transmittance (performance) originated from the variation in manufacturing. Therefore, more preferably θ_(s) satisfies 0°≤θ_(s)≤20°. As described above, in view of the problem of formation of moire fringes and manufacturing, further preferably 1°≤θ_(s)≤41.7°, and further more preferably, θ_(s) satisfies 1°≤θ_(s)≤20.0°.

In Examination Example 1, the result in one example is shown. However, image source units having other configuration such as the optical functional layer having another configuration showed similar tendency.

Examination Example 2-1

As Examination Example 2-1, an image source unit corresponding to the image source unit 10 described with reference to FIG. 1 was produced, and evaluations were carried out thereon. The specific shape was as follows.

<Base Material Layer>

Material and thickness: polycarbonate, thickness 130 μm

<Optical Functional Layer>

Pitch: 39 μm (P_(k) in FIG. 7)

Width of upper base of light absorbing portion: 4 μm (W_(a) in FIG. 7)

Width of lower base of light absorbing portion: 10 μm (W_(b) in FIG. 7)

Thickness of light absorbing portion: 102 μm (D_(k) in FIG. 7)

Thickness of optical functional layer: 127 μm

Material and refractive index of light transmissive portion: ultraviolet curable urethane acrylate of 1.56 in refractive index

Material and refractive index of light absorbing portion: carbon black-containing acrylic beads-dispersed ultraviolet curable urethane acrylate having a refractive index of 1.49, where 25 mass % of acrylic beads is dispersed in 100 mass % of the urethane acrylate

<Liquid Crystal Panel, Reflection Type Polarizing Plate, Light Guide Plate and Light Source>

A liquid crystal panel, reflection type polarizing plate, light guide plate and light source provided to a 6.5 inch liquid crystal display device (LQ065T5GG03, manufactured by SHARP CORPORATION) were used.

<Arrangement>

The layers were arrayed in the order shown in FIG. 1, and the extending direction of the light transmissive portion and the light absorbing portion of the optical sheet, and the extending direction of the transmission axes of the reflection type polarizing plate and the lower polarizing plate were coincided with each other (that is, θ_(s)=0° in FIG. 8).

Examination Example 2-2

Examination Example 2-2 was same as Examination Example 2-1, except that θ_(s) was changed to 10°.

Examination Example 2-3

Examination Example 2-3 was same as Examination Example 2-1, except that θ_(s) was changed to 90°.

Examination Example 2-4

Examination Example 2-4 was same as Examination Example 2-1, except that θ_(s) was changed to 45°.

A light source was turned on for each of the image units described above, and the brightness was measured from the front (automatic goniophotometer, GP-500, manufactured by MURAKAMI COLOR RESEARCH LABORATORY CO., Ltd.). Setting the brightness of the Examination Example 2-3 (θ₅=90°) as 100%, brightness of other examples was shown as percentages (brightness ratio). The value of the brightness corresponded to the transmittance ratio T_(p).

As a result, the brightness ratio of Examination Example 2-1 was 100.5%, the brightness ratio of Examination Example of 2-2 was 100.4%, and the brightness ratio of Examination Example 2-4 was 100.3%. The absolute values were different since the conditions were not exactly same as that of Examination Example 1. However, the same tendency was able to be obtained from the results of Examination Examples 2-1 to 2-4, as that of Examination Example 1.

It is noted that moire fringes were observed in Examination Example 2-1.

FIG. 14 is a view showing a fifth embodiment, and is a perspective view showing an image source unit 410 included in a display device. Other than the image source unit 410, the display device includes normal devices needed for functioning as a display device, such as a housing to accommodate the image source unit 410, a power source to operate the image source unit 410, and an electronic circuit to control the image source unit 410, whose descriptions are omitted. Hereinafter the image source unit 410 will be explained.

The image source unit 410 includes the liquid crystal panel 15, a surface light source device 420, and the functional film 40. In FIG. 14, the upper side of the drawing sheet is the observer side. To the liquid crystal panel 15 and the functional film 40, the same symbols as in the above-described image source unit 10 are used, and the explanations thereof are omitted, because they are same as in the image source unit 10 described above.

Next, the surface light source device 420 will be described. FIG. 15 shows a part of a cross-sectional view of the image source unit 410 cut along the line shown by XI-XI in FIG. 14.

The surface light source device 420 is a lighting device arranged on the opposite side from the observer side, which emits planer light to the liquid crystal panel 15. As is seen from FIGS. 14 and 15, the surface light source device 420 of this embodiment is also configured as an edge light type surface light source device, including a light guide plate 21, a light source 25, a light diffusion layer 26, a prism layer 27, an optical sheet 430, and a reflection sheet 39. Among them, to the components except the optical sheet 430, same symbols are used and explanations thereof are omitted, since they are the same as in the surface light source device 20 described above.

Next, the optical sheet 430 of this embodiment will be described. As can be seen from FIGS. 14 and 15, the optical sheet 430 includes: a base material layer 431 formed in a sheet; a prism layer 436 arranged on a face of the base material layer 431, the face to be the light guide plate side 21, that is, on the light input side face, functioning as an optical element layer; the optical functional layer 32 arranged on a face of the base material layer 431, the face being on the opposite side of the prism layer 436, that is, arranged on the light output side face; and the adhesive layer 35 arranged on the opposite side of the base material layer 431 of the optical functional layer.

As shown in FIGS. 14 and 15, in this embodiment, the base material layer 431 is a sheet-like member formed in a flat plate supporting the optical element layer 436 and the optical functional layer 32.

For the material of the base material layer 431, the same material of the base material layer 31 may be used.

In the optical element layer 436, a plurality of unit optical elements 437 are arranged in a manner to be arrayed along the light input face side of the base material layer 431. More specifically, the unit optical element 437 is a column-shaped member formed in a manner to extend in the back-to-front direction of the drawing sheet of FIG. 15, having the cross section shown in FIG. 15. The extending direction of the unit optical element 437 is same as the extending directions of the back face optical element 23 and the light transmissive portion 33 of the optical functional layer 32, and is orthogonal to the light guiding direction of the light guide plate 21, in the front view of the optical sheet 430. Therefore, a plurality of unit optical elements 437 are arrayed in the light guiding direction.

The longitudinal direction, which is the direction where the ridge line of the unit optical element 437 extends, is orthogonal to the transmission axis of the lower polarizing plate 14 of the liquid crystal panel 15, when the display panel is observed from the front (in the front view). Preferably, the longitudinal direction of the unit optical element 437 of the optical sheet 430 intersects at an angle of more than 45° and less than 135°, to the transmission axis of the lower polarizing plate 14 of the liquid crystal panel 15, in the front view. The angle mentioned herein means a smaller angle of the angles made by the longitudinal direction of the unit prism 437 and the transmission axis of the lower polarizing plate 14, that is, an angle of no more than 180°. Particularly in this embodiment, the longitudinal direction of the unit optical element 437 of the optical sheet 430 is preferably orthogonal to the transmission axis of the lower polarizing plate 14 of the liquid crystal panel 15; and the arrangement direction of the unit optical elements 437 is preferably parallel to the transmission axis of the lower polarizing plate 14 of the liquid crystal panel 15.

Next, the cross-sectional shape of the unit optical element 437 will be described. FIG. 16 is a partially enlarged view of the base material layer 431 and the optical element layer 436 shown in FIG. 14. Herein, “n_(d)” shows the normal direction of the layer face of the base material layer 431.

As is seen from FIG. 16, in this embodiment, the unit optical element 437 has an isosceles triangular cross section, in which the face of the light guide plate 21 side of the base material layer 431 is projecting. That is, the width of the unit optical element 437 in a direction parallel to the layer face of the base material layer 431 gets smaller as it gets farther from the base material layer 431 along the normal direction “n_(d)” of the base material layer 431. Therefore, the unit optical element 437 is an element convex to the light source 25 side in the image source unit 410.

In this embodiment, the outer contour of the unit optical element 437 forms a line symmetry with an axis parallel to the normal direction “n_(d)” of the base material layer 431 as a symmetrical axis; and the cross-sectional shape of the unit optical element 437 is an isosceles triangle. With this configuration, the brightness on the light output face of the optical sheet 430 can have a symmetrical angle distribution of brightness around the front direction, in the plane parallel to the arrangement direction of the unit optical element 437.

Here, the size of the unit optical element 437 is not particularly limited, and it is preferable that the vertex angle θ_(p) is in the range of from 50° to 80°, and the width W_(p) of the base and the pitch P_(p) are each in the range of from 10 μm to 100 μm.

In this embodiment, the unit optical element having the triangular-shaped cross section as above has been described; however, the cross-sectional shape of the unit optical element is not limited thereto. It may be a trapezoidal shape, changing the vertex part of the triangle into a shorter upper base. Further, the oblique line of the triangle may be a polygonal line or curved line. In addition, the unit optical element does not have to have a prism shape, and the oblique face may be a convex carved line or concave carved line.

The plurality of the unit optical elements may have the same cross-sectional shape, or may be arrayed to have different cross-sectional shapes with regularities, for example, having a different cross-sectional shape in every other pitch.

For the material of the unit optical element, the same material as that of the base material layer may be applied. Here, the refractive index is preferably no less than 1.55, in view of having an efficient total reflection of light at the oblique face and directing the light to the observer side. However, if the refractive index is too high, the material easily gets cracked. Therefore, the refractive index is preferably no more than 1.61, and more preferably no more than 1.58.

Next, the optical functional layer 32 will be described back to FIGS. 14 and 15. The optical functional layer 32 in this embodiment is same as the optical functional layer 32 of the image source unit 10 described above, except its orientation. Therefore the explanation thereof is omitted.

In the optical sheet 430, the adhesive layer 35 is layered on a face of the optical functional layer 32, the face being opposite from the face where the base material layer 431 is arranged. This adhesive layer 35 is same as the adhesive layer 35 of the optical sheet 30.

As described above, the optical sheet 430 includes the optical element layer 436 and the optical functional layer 32. The optical element layer 436 includes the unit optical elements 437 arrayed in a manner to be convex to the opposite side from the optical functional layer 32, across the base material layer 431. Here, it is preferable that the extending direction of the unit optical element 437 and the extending direction of the light transmissive portion 33 and the light absorbing portion 34 of the optical functional layer 32 form an angle in the range of no more than 10° in the front view of the optical sheet 430. This makes it possible to efficiently control light, as described later.

In this embodiment, an example in which the optical element layer 436 and the optical functional layer 32 are arranged on either side of the base material layer 431 is shown. However, the present invention is not limited thereto, and each of the optical element layer 436 and the optical functional layer 32 may separately have a base material layer, and the two base material layers may be attached to each other to form an optical sheet. When each of the optical element layer 436 and the optical functional layer 32 separately has a base material, the two base materials do not have to be attached to each other, and they may have a predetermined gap, or may just have contact with each other without being attached to each other. When the base materials are not attached to each other, a rough face similar to the rough face 31 a described above may be provided thereto.

The light traveled through the light guide plate 21 and the light diffusion layer 26 and emitted from the prism layer 27 enters the optical sheet 430. The unit optical element 437 of the optical sheet 430 has a light condensing function (function to change the direction of light closer to the normal line of the liquid crystal panel), in which the light entered the unit optical element 437 is totally reflected at the opposite face of the face where the light entered, and changes its direction. That is, as shown by L121 in FIG. 16, the light having entered the unit optical element 437 is totally reflected at the interface between the unit optical element 437 and air, based on their refractive index difference. The oblique side of the unit optical element 437 is inclined by θ_(p)/2 to the normal direction n_(d) of the sheet face (same as the normal line of the liquid crystal panel). Therefore, the reflection light at the interface has an angle to be closer to the normal line n_(d) than the light having entered the unit optical element 437.

Thus, at the face parallel to the arrangement direction of the unit optical elements 437 of the optical sheet 430, the optical element layer 436 can concentrate the moving direction of the transmitted light into a narrow angle range around the front direction side. Therefore, the brightness in the front direction can be increased by the optical function of the optical sheet 430.

As described, the optical element layer 436, which has the unit optical element 437 convex to the light input side, can efficiently concentrate light without having side lobe. After that, the light passes through the optical functional layer 32, the liquid crystal panel 15, and the functional sheet 40, and then is provided to the observer.

The optical sheet 430 described above efficiently condenses the light from the light guide plate 21, and light not condensed is absorbed by the light absorbing portion. Therefore the optical sheet 430 can efficiently provide proper light to the liquid crystal panel, and can greatly improve the use efficiency of light.

FIG. 17 is a view showing a sixth embodiment, and corresponds to FIG. 2. In this embodiment, an optical sheet 530 is applied to a surface light source device 520 of an image source unit 510. Other structure is same as the above-described image source units 10 and 410.

The optical sheet 530 includes the base material layer 431 and the optical element layer 436, in the same manner as in the optical sheet 430. However, the layer structure in a side closer to the liquid crystal panel 15 than the base material layer 431 is same as that of the optical sheet 30 of the image source unit 10. The reflection type polarizing plates 28, 28′ may be arranged between the base material layer 431 and the optical functional layer 32.

The image source unit 510 like this exerts the same effect as the effect described above.

Based on the optical sheets described above, optical sheets having the following layer structures were produced as Examination Examples 3 to 8.

Examination Example 3

From the observer side, layered were an adhesive layer, a base material layer for an optical functional layer, the optical functional layer (optical functional layer whose orientation was same as in the example in FIG. 17), a reflection type polarizing plate, a base material layer for an optical element layer, and the optical element layer.

Examination Example 4

From the observer side, layered were an adhesive layer, an optical functional layer (optical functional layer whose orientation was same as in the example in FIG. 15), a base material layer for the optical functional layer, a reflection type polarizing plate, a base material layer for an optical element layer, and the optical element layer.

Examination Example 5

From the observer side, layered were an adhesive layer, a base material layer for an optical functional layer, the optical functional layer (optical functional layer whose orientation was same as in the example in FIG. 17), a base material layer for an optical element layer, and the optical element layer.

Examination Example 6

From the observer side, layered were an adhesive layer, an optical functional layer (optical functional layer whose orientation was same as in the example in FIG. 15), a base material layer, and an optical element layer.

Examination Example 7

From the observer side, layered were an adhesive layer, a base material layer for an optical functional layer, the optical functional layer (optical functional layer whose orientation was same as in the example in FIG. 17), a reflection type polarizing plate, the prism sheet A having a layer of prism shape convex to the observer side as shown in FIG. 18 (vertex angle of the prism: 90°), and a light diffusing film.

Examination Example 8

From the observer side, layered were an adhesive layer, an optical functional layer (optical functional layer whose orientation was same as in the example in FIG. 15), a base material layer for the optical functional layer, a reflection type polarizing plate, the prism sheet A having a layer of prism shape convex to the observer side as shown in FIG. 18 (vertex angle of the prism: 90°), and a light diffusing film.

Here, specific shape in each example was as follows.

(Unit Optical Element)

pitch: 50 μm (P_(p) in FIG. 16)

vertex angle: 70° (θ_(p) in FIG. 16)

material and refractive index: ultraviolet curable urethane acrylate, refractive index 1.58

base material layer: polycarbonate, thickness 130 μm

(Optical Functional Layer)

pitch: 39 μm (P_(k) in FIG. 7)

width of upper base of light absorbing portion: 4 μm (W_(a) in FIG. 7)

width of lower base of light absorbing portion: 10 μm (W_(b) in FIG. 7)

thickness of light absorbing portion: 102 μm (D_(k) in FIG. 7)

thickness of optical functional layer: 127 μm

material and refraction ratio of light transmissive portion:ultraviolet curable urethane acrylate, refractive index 1.56

material and refraction ratio of light absorbing portion:carbon black-containing acrylic beads-dispersed ultraviolet curable urethane acrylate having a refractive index of 1.49, where 25 mass % of acrylic beads is dispersed in 100 mass % of the urethane acrylate

On the back face side of the optical sheet of each Examination Example, a light guide plate, a reflection sheet, and a light source were arranged as in the example in FIG. 15. The optical sheet was irradiated from the back face side with the edge light type light source with the light guide plate. A liquid crystal panel (6.5 inch, LQ065T5GG03, manufactured by SHARP CORPORATION) was arranged on the light output side of the optical sheet. The brightness was measured from the front (by luminance meter, LS-110, manufactured by Konica Minolta, Inc.).

In addition, the inclined angle (half-value angle) at which the value of brightness is half of the front brightness was measured. As to the half-value angle, the average of the upper side and lower side (direction in which the light transmissive portions were arrayed) seen from the front was taken.

TABLE 2 Front Half-value brightness angle Exam. Ex. 3 145% 60° Exam. Ex. 4 139% 60° Exam. Ex. 5 137% 45° Exam. Ex. 6 130% 45° Exam. Ex. 7 80% 50° Exam. Ex. 8 76% 50°

As is seen from Table 2, in Examination Examples 3 to 6, the front brightness was able to be increased more, compared to the front brightness in Examination Examples 7 and 8.

In Examination Examples 9 to 14, the base material of the optical functional layer 32 was polycarbonate, and the average coefficient of linear expansion and the average expansion of the laminate including at least the base material layer and the optical functional layer were changed, to evaluate the performance. Table 3 represents the layer structures and main characteristics of each example. Examination Examples 9 to 11 were examples of including only the base material layer and the optical functional layer. Examination Examples 12 to 14 were examples of further layering the adhesive layer, the reflection type polarizing plate, and a transparent protection plate.

A layer shown in an upper row in Table 3 was layered closer to the observer side, and a layer shown in a lower row in Table 3 was layered closer to the light source side as shown in “Position of layer” in Table 3. The blanks in Table 3 represent that corresponding layers were not included.

TABLE 3 Position Exam. Exam. Exam. Exam. Exam. Exam. of layer Name of layer Layer structure Ex. 9 Ex. 10 Ex. 11 Ex. 12 Ex. 13 Ex. 14 (observer Layer having 25 25 side) rough face | Base material layer Material PC PC PC PC PC PC | Thickness (μm) 130 130 250 100 100 100 | Coefficient of Parallel 9.15 8.63 7.97 9.52 8.79 10.4 | linear direction | expansion Orthogonal 7.96 8.41 7.64 8.48 8.39 11.3 | (1/K)*10⁻⁵ direction | Linear Parallel direction 1.5 1.6 1.4 1.8 1.8 2.0 | expansion Orthogonal 1.4 1.5 1.4 1.6 1.2 2.2 | (%) direction | Optical functional Pitch (P_(k) in FIG. 7, μm) 39 39 39 43 43 43 | layer Width of upper base of 4 4 4 8 8 8 | light absorbing portion | (W_(a) in FIG. 7, μm) | Width of lower base of 10 10 10 14 14 14 | light absorbing portion | (W_(b) in FIG. 7, μm) | Thickness of light absorbing 102 102 102 96 96 90 | portion (D_(k) in FIG. 7, μm) | Thickness of optical functional 127 127 127 127 127 127 | layer (μm) | Layer having rough face Material PC PC PC | (reference numeral Thickness (μm) 25 25 25 | 31′ in FIG. 9) | Refection type Thickness (μm) 100 35 35 | polarizing plate ↓ Adhesive layer Thickness (μm) 20 20 20 (light source Transparent Thickness (μm) 100 100 100 side) protection plate

“Layer having rough face” on the top in the table was a layer for forming the rough face 31 a shown in FIG. 7, which was included in Examination Examples 10 and 11. This rough face was measured using “Mitutoyo: SJ-301”, a contact-type surface roughness tester, and its average roughness Ra was 0.28 μm.

“PC” in the row of “Base material layer” means polycarbonate.

“Parallel direction” in “coefficient of linear expansion” and “linear expansion” represents a value in the extending direction of the light transmissive portion and the light absorbing portion.

“Orthogonal direction” in “Coefficient of linear expansion” and “Linear expansion” represents a value in the direction orthogonal to the extending direction of the light transmissive portion and the light absorbing portion.

“Coefficient of linear expansion” and “Linear expansion” are the mean values within the range of −50° C. and 130° C.

Here, the coefficient of linear expansion and the linear expansion were measured by the method including two steps, using a thermomechanical analyzer (TMA-60 by SHIMADZU CORPORATION) in a nitrogen gas atmosphere under the conditions of the constant load-rate, a tension mode, and the initial load of 10 g/mm².

In the first step, the heating rate was −10 (° C./min), the target temperature was −55° C. and the retention time was 15 minutes.

In the second step, the heating rate was 10 (° C./min), the target temperature was 135° C. and the retention time was 0 minute.

The light absorbing portion in “Optical functional layer” was directed so that the upper base thereof was on the observer side and the lower base thereof was on the light source side.

The light transmissive portion was formed of ultraviolet curable urethane acrylate, and its refractive index after cured was 1.56.

In contrast, the light absorbing portion was carbon black-containing acrylic beads-dispersed ultraviolet curable urethane acrylate having a refractive index of 1.49, where 25 mass % of acrylic beads was dispersed in 100 mass % of the urethane acrylate.

A rough face in “Layer having rough face (reference numeral 31′ in FIG. 9)” was measured using “Mitutoyo: SJ-301”, a contact-type surface roughness tester, and its average roughness Ra was 0.28 μm.

The laminate and a frame surrounding the periphery of the laminate were made for each of Examination Examples 9 to 14. The laminate was arranged inside the frame.

This frame was made so that the inner shape of all the sides was 2% larger than the peripheral shape of the laminate at 25° C.

The state where the laminate was arranged in the frame was kept in an atmosphere at −40° C. for 0.5 hours, and in an atmosphere at 95° C. for 0.5 hours, which was defined as one turn. This turn was repeated 1000 times.

As a result, crinkles occurred to the laminate in Examination Example 14 while no crinkles occurred in Examination Examples 9 to 13.

REFERENCES SIGN LIST

-   -   10, 310, 410, 510 image source unit     -   15 liquid crystal panel     -   20, 320, 420, 520 surface light source device     -   21 light guide plate     -   25 light source     -   26 light diffusion layer     -   27 prism layer     -   28 reflection type polarizing plate     -   30, 130, 230, 430, 530 optical sheet     -   31 base material layer     -   32 optical functional layer     -   33 light transmissive portion     -   34 light absorbing portion (in-between portion) 

What is claimed is:
 1. A laminate comprising: a polarizing plate; and an optical sheet arranged on one surface side of the polarizing plate, wherein the optical sheet includes a base material layer, and an optical functional layer arranged on one face of the base material layer, the optical functional layer includes a plurality of light transmissive portions extending in an extending direction parallel to a plane of a face of the base material layer, each light transmissive portion having a predetermined cross section, and arrayed in a direction different from the extending direction thereof at predetermined intervals, and at least one in-between portion formed in each of the intervals of adjacent light transmissive portions, an angle formed by an extending direction of a transmission axis parallel to a plane of the polarizing plate, and the extending direction of the light transmissive portions is 1° to 41.7° in a front view of the laminate, and the base material layer is formed of polycarbonate, an average coefficient of linear expansion of the laminate within a range of −50° C. and 130° C. is 0 (1° C.) to 1×10⁻⁴ (1/° C.), and an average linear expansion of the laminate within a range of −50° C. and 130° C. is 0% to 2%.
 2. The laminate according to claim 1, wherein a refractive index of at least one in-between portion is no less than 1.47 and a difference between a refractive index of an adjacent light transmissive portion and the refractive index of the at least one in-between portion is in a range from 0.05 to 0.14.
 3. The laminate of claim 1, wherein a pitch of at least one light transmissive portion and an adjacent in-between portion is in a range from 20 μm to 100 μm.
 4. An image source unit comprising the laminate according to claim 1, the laminate further including a liquid crystal layer.
 5. A display device formed of a housing in which the image source unit according to claim 4 is placed.
 6. A laminate comprising: a reflection type polarizing plate; and an optical sheet arranged on one surface side of the reflection type polarizing plate, wherein the optical sheet includes a base material layer, and an optical functional layer arranged on one face of the base material layer, the optical functional layer includes a plurality of light transmissive portions extending in an extending direction parallel to a plane of a face of the base material layer, each light transmissive portion having a predetermined cross section, and arrayed in a direction different from the extending direction thereof at predetermined intervals, and at least one in-between portion formed in each of the intervals of adjacent light transmissive portions, an angle formed by an extending direction of a transmission axis parallel to a plane of the reflection type polarizing plate, and the extending direction of the light transmissive portions is 1° to 41.7° in a front view of the laminate, and the base material layer is formed of polycarbonate, an average coefficient of linear expansion of the laminate within a range of −50° C. and 130° C. is 0 (1/° C.) to 1×10′ (1/° C.), and an average linear expansion of the laminate within a range of −50° C. and 130° C. is 0% to 2%.
 7. The laminate according to claim 6, wherein a refractive index of at least one in-between portion is no less than 1.47 and a difference between a refractive index of an adjacent light transmissive portion and the refractive index of the at least one in-between portion is in a range from 0.05 to 0.14.
 8. The laminate of claim 6, wherein a pitch of at least one light transmissive portion and an adjacent in-between portion is in a range from 20 μm to 100 μm.
 9. An image source unit comprising the laminate according to claim 6, the laminate further including a liquid crystal layer.
 10. A display device formed of a housing in which the image source unit according to claim 9 is placed. 